US 2015.0027999A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2015/0027999 A1 Yamaguchi et al. (43) Pub. Date: Jan. 29, 2015

(54) COMBINED METHOD AND Publication Classification COMBINED MACHINING DEVICE (51) Int. Cl. B23K IO/00 (2006.01) (71) Applicant: KOMATSU INDUSTRIES B23Cl3/12 (2006.01) CORPORATION, Kanazawa-shi, B23K 37/08 (2006.01) Ishikawa (JP) (52) U.S. Cl. CPC ...... B23K 10/00 (2013.01); B23K 37/08 (72) Inventors: Yoshihiro Yamaguchi, Kaga-shi (JP); (2013.01); B23C 3/12 (2013.01) Kazuyuki Kitamura, Komatsu-shi (JP); USPC ...... 219/12144 Keita Kondo, Komatsu-shi (JP) (57) ABSTRACT A method of a cut member out of an original sheet by (21) Appl. No.: 14/374,401 means of thermal cutting and machining, and includes a hole cutting process, a finishing process, and an outer periphery cutting process. During the hole-cutting process, a hole is (22) PCT Fled: Feb. 18, 2013 created in the original sheet by means of thermal cutting while leaving a machining allowance in addition to the finished size (86) PCT NO.: PCT/UP2013/053818 of the hole. During the finishing process, a cutting is inserted into the hole which has been created through the S371 (c)(1), hole-cutting process, and the is guided along the (2) Date: Jul. 24, 2014 inner circumference of the hole so as to cut the thermally-cut end surface in order to machine the hole to the finished size. (30) Foreign Application Priority Data During the outer periphery-cutting process, the outer periph ery of the cut member is cut by means of thermal cutting to Mar. 28, 2012 (JP) ...... 2012-073222 take the cut member out of the original sheet.

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Patent Application Publication Jan. 29, 2015 Sheet 1 of 11 US 2015/0027999 A1

Patent Application Publication Jan. 29, 2015 Sheet 2 of 11 US 2015/0027999 A1

Patent Application Publication Jan. 29, 2015 Sheet 3 of 11 US 2015/0027999 A1

Controller

21 DX-axis motor 17

Hole-cutting Confirmation Plasma power functional functional supply unit unit Finishing functional unit

First periphery-cutting Z-axis motor functional unit

MZ2 Machining line data acquiring unit Second Z-axis motor

Automatic program device

FIG. 3 Patent Application Publication Jan. 29, 2015 Sheet 4 of 11 US 2015/0027999 A1

Machining start

Cut hole with plasma

Confirm original sheet front S2 surface height position

Confirm presence Yes or absence of end material

Remove end S4 material

S5 Machine cutting with

Outer periphery S6 cutting with plasma

Machining end

FIG. 4 Patent Application Publication Jan. 29, 2015 Sheet 5 of 11 US 2015/0027999 A1

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(b) Patent Application Publication Jan. 29, 2015 Sheet 6 of 11 US 2015/0027999 A1

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(c) Patent Application Publication Jan. 29, 2015 Sheet 7 of 11 US 2015/0027999 A1

FIG. 6 Patent Application Publication Jan. 29, 2015 Sheet 8 of 11 US 2015/0027999 A1

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(b) Patent Application Publication Jan. 29, 2015 Sheet 9 of 11 US 2015/0027999 A1 FIG. 8

FIG. 9

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19 Patent Application Publication Jan. 29, 2015 Sheet 10 of 11 US 2015/0027999 A1

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FIG. 10 Patent Application Publication Jan. 29, 2015 Sheet 11 of 11 US 2015/0027999 A1

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FIG. 11 US 2015/0027999 A1 Jan. 29, 2015

COMBINED MACHINING METHOD AND 1961 15. That is, movement and vibration of the original sheet COMBINED MACHINING DEVICE are prevented by the provision on the machining head of a mechanism for pressing down the original sheet, because the CROSS-REFERENCE TO RELATED machining head having the tool mounted thereon moves APPLICATIONS in the vertical direction during machining. Moreover, the 0001. This application is a U.S. National stage application above mechanism can be achieved with a simple configura of International Application No. PCT/JP2013/053818, filed tion. on Feb. 18, 2013. This U.S. National stage application claims 0011. However, in another type of machining, such as end priority under 35 U.S.C. S 119(a) to Japanese Patent Applica mill machining, the machining head must move in a horizon tion No. 2012-073222, filed in Japan on Mar. 28, 2012, the tal direction and thus the machining head cannot be equipped entire contents of which are hereby incorporated herein by with a mechanism to press down the original sheet. Further, reference. while drill machining does not exert a force in the horizontal direction, end mill machining does exert a force in the hori BACKGROUND Zontal direction. Therefore, end mill machining requires more rigidity of the machine main body than drill machining 0002 1. Field of the Invention does and in addition, a strong clamping mechanism is needed 0003. The present invention relates to a combined machin to Suppress movement of the original sheet in the horizontal ing method and in particular to a combined machining direction. As a result, a combined machining device for per method involving a hole in an original sheet by forming various types of machining, Such as drill machining means of thermal cutting and machining, and removing a cut and end mill machining, is provided with a separate large member including the hole from the original sheet. clamping mechanism as disclosed in Japanese Laid-Open 0004. The present invention further relates to a combined Patent Publication No. S59-196115. machining device for implementing the above combined 0012. A device having ahead for drill machining provided machining method. injuxtaposition with a thermal cutting device is able to forgo 0005 2. Background Information a large clamping mechanism as described above. However, 0006 Welded structures for configuring main body frames multiple drill having corresponding diameters need to for bridges, construction machinery, and industrial machin be prepared to form holes with various diameters and thus an ery and the like are obtained by taking out cut members of automatic tool changer (ATC) is required. As a result, the various shapes from an original sheet. Thermal cutting. Such expense of the entire device increases. as , gas cutting, or that is pro 0013 The device in Japanese Laid-open Patent Publica grammed to make a cut of any shape, is used when taking out tion No. H09-216021 requires punches corresponding to vari this type of cut member. ous types of hole diameters and thus this device also requires 0007 Japanese Laid-Open Patent Publication No. S59 an automatic tool changer. Therefore, the manufacturing cost 1961 15 discloses a combined machining device equipped of the device is similarly very high. with a machining head onto which a cutting tool. Such as a 0014 Problems of the conventional combined machining drill or and end mill, can be mounted, the machining head devices having a machining head for thermal cutting and a being different from a machining head for thermal cutting machining head for machining in addition to the above prob having installed thereon a plasma torch, a gas torch, or a laser lems are described below. head and the like. In addition to thermal cutting, this type of 0015. A machine main body for holding the machining combined machining device is used for machining complex heads requires high rigidity due to a machining reaction force precision holes which cannot be processed by thermal cut from a large amount of cutting due to the machining. More ting, holes which are determined according to standards for over, the provision of a clamping mechanism for clamping the machining, such as holes for joints in steel frames for con original sheet to the loading table or of a mechanism for struction, or grooves and the like for . pressing down the original sheet onto the loading table is 0008 Japanese Laid-open Patent Publication No. H09 required, and the machining equipment becomes more com 216021 also discloses a combined machining device having a plex, which raises costs. machining head and a laser machining head. This 0016. An ATC is required for drill machining and the costs device forms pilot holes in a plate by means of the laser of the machining equipment increases. machining head and then performs finishing on the pilot hole 0017. Because the cutting amount during machining is by means of the punch machining head. large in a conventional combined machining apparatus, rela tively large thread-like or spiral chips are produced even SUMMARY though the clearance (cutting height) between the plasma 0009. To perform machining, such as cutting machining, torch and the original sheet for example is several millime with high efficiency, the combined machining device requires ters. These chips become scattered over the original sheet and a high-output motor and a high rigidity frame for bearing a hinder the travel of the torches during thermal cutting. In large machining reaction force. The combined machining particular, needle-shaped thread-like or spiral chips cannot be device is also provided with a clamping mechanism for secur blown away with gas or removed by a brush when the chips ing the original sheet on a loading table to limit movement become caught in grooves cut in the thermal cutting. and vibration of the original sheet due to the reaction forces 0018. Because the cutting amount during machining is during machining. Therefore, the manufacturing cost of the large in the conventional combined machining apparatus, the device is very high. machining speed is slower than the thermal cutting and over 0010 When forming a hole in an original sheet by means all productivity is reduced due to the combined machining. of , the clamping mechanism can be omitted as dis 0019. When machining a large original sheet, the original closed in Japanese Laid-Open Patent Publication No. S59 sheet needs to be carried onto the loading table with a crane US 2015/0027999 A1 Jan. 29, 2015 and then needs to be positioned with respect to the clamping the hole from the hole-cutting process is included between the mechanism with the crane. It is not practical to perform hole-cutting process and the finishing process. positioning of the original sheet by means of a crane in this 0027. When a plurality of cut members are present, the way. machining may be performed in the following order. 0020. A combined machining apparatus that is able to 0028 Processes of hole-cutting finishing X outer perform both thermal cutting and machining cannot be used periphery-cutting are implemented in order for each cut for the purpose of removing a large cut member from a large member. original sheet (e.g., an original sheet with a length exceeding 0029. The processes of hole-cutting » finishing are imple 6 m) used in bridges, construction machinery or industrial mented altogether on the plurality of cut members, and next machinery even when applied to a relatively small original the outer periphery-cutting is implemented altogether on the sheet that can be clamped in a simple manner, due to the above problems. plurality of cut members. 0030. After the hole-cutting is repeated and the finishing 0021 Particular reasons for the impracticability of a com machining is repeated, the outer periphery-cutting is imple bined machining apparatus with end mill machining and ther mented altogether. mal cutting machinery are described below. 0031. As can be seen from the above description, the outer 0022. The original sheet cannot be secured by a clamping periphery-cutting process is necessarily implemented after mechanism on the loading table by merely placing the origi the finishing process. That is, the point in time for implement nal sheet on the loading table in a thermal cutting machine. ing the finishing machining is before the outer periphery That is, a clamping mechanism is not provided from the cutting, and the cut members need to be united with the operation itself for removing a plurality of cut members from original sheet. a large original sheet, and moreover, a load in the horizontal direction is not exerted on the original sheet when performing 0032. In the machining method described above, a small thermal cutting operations. Moreover, one reason that the machining allowance remains during the formation of the clamping mechanism is not provided is that the position of a hole by thermal cutting in the hole-cutting process, whereby large original sheet on the loading table is not very precise a load during the cutting machining can be reduced in the because the original sheets are replaced by using a crane in finishing process. As a result, the rigidity of the frame in a operations to replace the original sheets. device for implementing the machining method can be reduced and a motor for the machining can be made more 0023. Accordingly, when performing drill machining or compact in comparison to the conventional means. Further machining, while a mechanism for pressing the more, at the point in time of implementing the finishing original sheet may be provided around a drillora punch mold, machining of the hole by means of the machining, the cut a simple mechanism for pressing the original sheet cannot be member including the hole section when performing the fin provided when performing end mill machining as described ishing machining is not cut away from the original sheet above because the tool itself moves in the horizontal direc because the finishing machining is before the outer periphery tion. Furthermore, a machining load in the horizontal direc cutting process. As a result, the original sheet is held on the tion is produced during end mill machining. loading table due to the dead weight of the original sheet 0024. As described above, the conditions required for the when the original sheet is particularly large and the machin operation characteristics for end mill machining and thermal ing allowance and the diameter of the cutting tool can be set cutting machining are different, and therefore a combined appropriately, whereby movement of the original sheet due to machining apparatus with end mill machining equipment and a machining reaction force can be prevented even without thermal cutting equipment that does not have a clamping clamping. mechanism is not practical. 0033. When executing hole cutting, end material of an 0025. An object of the present invention is to enable ther inside section of the hole normally falls downward from gaps mal cutting and machining to be performed on large original between the crosspieces of the table. However, when the hole sheets in particular by means of a simple and inexpensive cutting is implemented when straddling a crosspiece, the end combined machining device. material remains on the crosspiece and may remain in the hole 0026. A combined machining method according to a first due to the end material catching onto the inner peripheral aspect of the present invention is a method for forming a hole Surface of the hole. In Such a condition, the tool for cutting in in an original sheet by means of thermal cutting and machin the finishing process cannot be inserted into the inside section ing and taking out a cut member including the hole from the of the hole. Thus, confirming whether or not end material is original sheet. The method includes a hole-cutting process, a remaining in the inside section of the cut hole is performed in finishing process, and an outer periphery-cutting process. this method. When end material is remaining, the finishing During the hole-cutting process, a hole is formed in the origi process is not executed or processing is executed so that the nal sheet by means of thermal cutting while leaving a machin finishing process is executed after the end material is ing allowance relative to a finished size of the hole. During the removed. finishing process, a cutting tool is inserted into the hole which 0034. A combined machining method according to a sec has been formed in the hole-cutting process, and the cutting ond aspect of the present invention is related to the method of tool is guided along the inner peripheral Surface of the hole to the first aspect, wherein the thermal cutting during the hole cut the thermally-cut end Surface, and machining the hole to cutting process and the outer periphery-cutting process is the finished size. During the outer periphery-cutting process, plasma cutting that generates a plasma arc on the front Surface the outer periphery of the cut member is cut by means of side of the original sheet, and the hole-cutting process thermal cutting to take the cut member out of the original involves thermal cutting so that a machining allowance sheet. Furthermore, a confirmation process for confirming remains on an original sheet front Surface side end section of whether or not thermally-cut end material is remaining inside the hole. US 2015/0027999 A1 Jan. 29, 2015

0035. When forming a hole by plasma cutting, the diam the original sheet, it was found that, when the cutting tool eter of the original sheet front surface side of the hole that is diameter is made to be two times or less than the plate thick the side that the plasma arc makes contact with tends to be ness, favorable finishing machining for various original larger than the diameter on the rear Surface side. sheets is made possible at a high machining speed within a 0036. Accordingly, the method according to the second range in which the original sheet does not vibrate nor move. aspect involves thermal cutting so that the machining allow 0047. The lower limit of the cutting tool diameter is lim ance remains in the original sheet front Surface side end ited by the diameter of an attachment shaft. The attachment section of the hole in the hole-cutting process. In this case, by shaft diameter is determined on the basis of the strength that making a target size on the hole front Surface side the approxi allows the attached cutting tool to function as a tool. There mate finished size in the hole-cutting process, the cutting fore, the cutting tool diameter is naturally equal to or greater amount in the finishing process can be greatly reduced. than the diameter having the strength to function as the tool. 0037. A combined machining method according to a third 0048. The diameter of the cutting tool is made to be two aspect of the present invention is related to the method of the times or less than the thickness of the original sheet in the first aspect, wherein the thermal cutting during the hole method according to the fifth aspect in this case. The cutting cutting process and the outer periphery-cutting process is tool diameter is more preferably one time or less than the laser cutting that irradiates a laser or gas cutting that emits a thickness of the original sheet. gas from the front Surface of the original sheet, and the hole 0049. A combined machining method according to a sixth cutting process involves thermal cutting so that a machining aspect of the present invention is related to any of the first to allowance remains on an original sheet rear Surface side end fifth aspects, and further includes a measuring process for section of the hole. measuring a height position of the hole as a previous process 0038. When forming a hole by means of laser or gas cut of the finishing process. Moreover, the height position of the ting, the diameter on the original sheet front Surface side of cutting tool is controlled in the finishing process on the basis the hole which is the laser irradiation side or the gas emission of measurement results from the measuring process and plate side tends to be smaller than the diameter of the rear surface thickness data of the original sheet. side, which is the reverse of the tendency in plasma cutting. 0050. The height of the original sheet placed on the load 0039. Accordingly, the method according to the third ing table in the thermal cutting machine is not uniform due to aspect involves thermal cutting so that the machining allow dross adhered to crosspieces of the table and due to warping ance remains in the original sheet rear Surface side end section of the hole in the hole-cutting process. In this case, by making of the original sheet. The height of the upper surface of the a target size on the hole rear Surface side the approximate crosspieces may have a variation of several millimeters since finished size in the hole-cutting process, the cutting amount in the crosspieces of the table are consumable goods. the finishing process can be greatly reduced. 0051. When performing machining on the inner peripheral 0040. A combined machining method according to a surface (cutting end surface) of the hole on the basis of data of fourth aspect of the present invention is related to any of the a predetermined table surface height and the thickness of the first to third aspects, wherein machining from the hole-cutting original sheet under Such conditions, an un-machined portion process to the outer periphery-cutting process is performed may remain near the bottom of the hole or conversely a without clamping the original sheet. crosspiece or dross may be cut. In this way, the machining 0041 As described above, the machining reaction force speed needs to be reduced when it is assumed that the cross exerted on the original sheet during machining is reduced by piece or the dross may be cut, and furthermore the rigidity of implementing the method of the present invention. As a the frame needs to be increased since the machining reaction result, machining can be performed without clamping the force increases. original sheet. 0.052 Accordingly, the height position of the hole is mea 0042. A combined machining method according to a fifth Sured before the finishing process in the method according to aspect of the present invention is related to any of the first to the sixth aspect, and the height position of the cutting tool is fourth aspects, wherein the finishing process involves using a controlled on the basis of the measurement results. As a result, rotating cutting tool to cut the thermally-cut end Surface of the the inner peripheral surface of the hole can be cut precisely. hole. The cutting tool diameter is two times or less than the 0053. The height position of the hole can be easily mea thickness of the original sheet. Sured by measuring the front Surface height of the original 0043. Normally, an item with a large tool diameter is com sheet near the hole. monly used in a possible range because the cutting speed (tool 0054. A combined machining method according to a sev diameter X spindle rotation speed) is increased and machining enth aspect of the present invention is related to any of the first efficiency is improved correspondingly when a tool with a to sixth aspects, and further includes a confirmation process large tool diameter is used. for confirming whether or not thermally-cut end material 0044. However, when performing machining without remains inside the hole in the hole-cutting process between clamping the original sheet, a technique to prevent the origi the hole-cutting process and the finishing process. nal sheet from vibrating is required. 0055 When executing hole cutting, normally end material 0045. The deadweight of the original sheet increases as the of an inside section of the hole falls downward from gaps plate thickness of the original sheet increases and, thus, a between the crosspieces of the table. However, when the hole constraining force (holding force on loading table) increases. cutting is implemented when straddling a crosspiece, the end Therefore, there is a relationship between the plate thickness material remains on the crosspiece and may remain in the hole and the diameter of the cutting tool when performing machin due to the end material catching onto the inner peripheral ing without clamping the original sheet. Surface of the hole. In Such a condition, the tool for cutting in 0046 Based on results of machining testing by the inven the finishing process cannot be inserted into the inside section tors, when performing cutting machining without clamping of the hole. US 2015/0027999 A1 Jan. 29, 2015

0056. Accordingly, the method according to the seventh 0064. In this combined processing device, a small machin aspect involves confirming whether or not end material is ing allowance remains during the formation of the hole by remaining in the inside section of the cut hole. When end thermal cutting in the hole-cutting process, whereby a load material is remaining, the finishing process is not executed or during the cutting machining can be reduced in the finishing processing is executed so that the finishing process is process. As a result, the rigidity of the device frame for executed after the end material is removed. implementing the cutting machining can be reduced and a 0057. A combined machining method according to an motor for the machining can be made more compact in com eighth aspect of the present invention is related to the the parison to the conventional means. Moreover, a clamping method of the first to sixth aspects, wherein the confirmation mechanism for pressing down the original sheet is unneces process is performed by inserting the cutting tool used in the sary finishing process into the hole. 0065. A combined machining device according to a 0058. A special sensor is not required in this case because twelfth aspect of the present invention is related to the device the presence of end material inside the hole is confirmed by of the eleventh aspect, wherein the second head has a cutting means of the cutting tool used in the finishing process. tool having a diameter that is two times or less than the thickness of the original sheet. 0059 A combined machining method according to a ninth 0066. As mentioned above, a reaction force exerted on a aspect of the present invention is related to any of the methods main shaft to which the tool is attached and on the original from the first to eighth aspects, wherein the finishing process sheet decreases in correspondence to a reduction in the tool involves cutting the thermally-cut end surface of the hole diameter. As a result, vibration during machining can be formed in the hole-cutting process with an end mill. further suppressed due to the diameter of the cutting tool 0060. Because the cut end surface of the hole is cut by being two times or less than the thickness of the original sheet. end- in this case, various hole diameters can be treated The cutting tool diameter is more preferably one time or less with one tool. than the thickness of the original sheet. 0061. A combined machining method according to a tenth 0067. A combined machining device according to a thir aspect of the present invention is related to any of the first to teenth aspect of the present invention is related to the eleventh ninth aspects, wherein the finishing process involves driving or twelfth aspect, wherein the control unit further includes a the rotating cutting tool with an air motor. confirmation functional unit for confirming whether or not 0062 By rotating the cutting tool with an air motor, num thermally-cut end material is remaining inside the hole. ber of tool rotations can be decreased when the machining 0068 A combined machining device according to a four load is increased. As a result, movement of the original sheet teenth aspect of the present invention is related to the device can be further suppressed. of the eleventh or twelfth aspect, wherein the control unit 0063 A combined machining device according to an elev confirms the presence of the end material by inserting the enth aspect of the present invention is a device for forming a cutting tool attached to the second head into the hole. hole in an original sheet by means of thermal cutting and 0069. A combined machining device according to a fif machining and taking out a cut member including the hole teenth aspect of the present invention is related to the device from the original sheet, wherein the device comprises: a load of the eleventh to fourteenth aspects, wherein an end mill is ing table on which the original sheet is loaded; a first head for attached to the second head. performing thermal cutting on the original sheet in a state of 0070 A combined machining device according to a six not being clamped on the loading table; a second head for teenth aspect of the present invention is related to any of the performing machining on the original sheet in a state of not eleventh to fifteenth aspects, wherein the second head has an being clamped on the loading table; a movement mechanism air motor for driving the cutting tool. for moving the first and second heads in a horizontal direction 0071. By rotating the cutting tool with an air motor, the and a vertical direction relative to the loading table, a height machining load can be increased and the tool rotation speed position detection sensor for detecting a vertical direction can be decreased. As a result, movement of the original sheet position of the original sheet loaded on the loading table; and can be further suppressed. a control unit for controlling relative movement of the first 0072 According to the above aspects of the present inven and second heads relative to the loading table and for control tion, thermal cutting and machining to be performed espe ling the thermal cutting and the machining by the first and cially on large original sheets is enabled by means of a simple second heads. The control unit has a hole-cutting functional and inexpensive combined machining device. unit, a finishing functional unit, and an outer periphery-cut ting functional unit. The hole-cutting functional unit forms a BRIEF DESCRIPTION OF DRAWINGS hole in the original sheet by means of thermal cutting while leaving a machining allowance relative to the finished size of 0073 FIG. 1 is a view of an external configuration of a the hole. The finishing functional unit inserts a cutting tool combined machining device according to a first exemplary into the hole which has been formed in the hole-cutting pro embodiment of the present invention. cess, and guides the cutting tool along the inner peripheral 0074 FIG. 2 is a front view of the combined machining surface of the hole to cut the thermally-cut end surface, and device. machining the hole to the finished size. The outer periphery 0075 FIG. 3 is a system block diagram of the combined cutting functional unit cuts the outer periphery of the cut machining apparatus. member by means of thermal cutting and taking out the cut 0076 FIG. 4 illustrates operating procedures of a com member from of the original sheet. Furthermore, the control bined machining method according to the first exemplary unit has a confirmation functional unit for confirming embodiment of the present invention. whether or not thermally-cut end material is remaining inside 0077 FIG. 5A illustrates a disposition of components dur the hole. ing combined machining. US 2015/0027999 A1 Jan. 29, 2015

0078 FIG. 5B illustrates a disposition of components dur W0 is not easily moved during cutting, is used as the end mill ing combined machining. 19 in this exemplary embodiment. 007.9 FIG. 6 is a cross-sectional view for explaining a hole 0093. As mentioned above, based on results of machining shape due to plasma cutting. testing by the inventors, when performing cutting machining 0080 FIG. 7 is a view for explaining an action for detect without clamping the original sheet, it was found that, when ing the height position of an original sheet. the cutting tool diameter is made to be two times or less than 0081 FIG. 8 is a schematic plan view of a finishing pro the plate thickness, favorable finishing machining on various CCSS, original sheets is made possible at a high machining speed 0082 FIG.9 is a cross-sectional view of an example when within a range in which the original sheet does not vibrate nor machining a plurality of times in the axial direction during the OW. finishing process. (0094. The diameter of the end mill 19 as a result is pref 0083 FIG. 10 is a cross-sectional view of an example erably two times or less than the plate thickness of the original when machining a plurality of times in the radial direction sheet W0, or more preferably one time or less than the plate during the finishing process. thickness of the original sheet W0. 0084 FIG. 11 is a plan view for explaining up-cutting and 0.095 An air motor is used as the second Z-axis motor MZ2 down-cutting in the finishing process. in this exemplary embodiment. When there is a large machin ing allowance and the load torque is high when using an DESCRIPTION OF EXEMPLARY electric motor, cutting machining is carried out without a EMBODIMENTS reduction in rotation speed when there is an excess of motor capacity. As a result, there is a possibility that the original Configuration of Combined Machining Device sheet W0 may move because the original sheet W0 is not clamped during cutting machining in accordance with the 0085 FIG. 1 illustrates an overall configuration of a com exemplary embodiments of the present invention. bined machining device 1 according to a first exemplary 0096 Conversely, the rotation speed of the motor embodiment of the present invention. FIG. 2 illustrates a front decreases when the load torque increases if the end mill 19 is schematic view of the combined machining device 1. driven by an air motor. Therefore, as mentioned above, cut I0086. The combined machining device 1 is provided with ting is performed at a low rotation speed without forcefully a loading table 2 on which a steel plate W0 that is an original performing the cutting at a fixed rotation speed when there is sheet is loaded, a plasma torch (first head) 3 for thermal a large machining allowance. As a result, movement of the cutting, ahead (second head) 4 for machining, a height detec original sheet W0 can be prevented and machining can be tion sensor 5, and a controller 6. performed accurately without clamping the original sheet 0087. The following is an explanation of taking out a plu WO. rality of cut members W1, W2, each having a hole H from the 0097. The height detection sensor 5 is supported on the original sheet W0 by means of the combined machining Y-axis cart 13 and is movable in the Z-axis direction. The device 1. mechanism for driving the height detection sensor 5 in the 0088 A plurality of crosspieces 7 are arranged on the top vertical direction is omitted. Surface of the loading table 2 and processed end material is 0098. According to the above configuration, the plasma allowed to fall down from gaps between the crosspieces 7. torch 3 and the machining head 4 are capable of being moved The space above the loading table 2 is connected to a dust to any position in the horizontal direction (X- and Y-axis collector, which is not illustrated. directions) and in the vertical direction (Z-axis direction) 0089. An X-axis rail 10 is arranged beside the loading relative to the original sheet W0 loaded on the loading table 2. table 2. The X-axis rail 10 supports an X-axis cart 11 in a That is, a movement mechanism for moving the plasma torch manner that allows movement along the X-axis. AY-axis arm 3 and the machining head 4 in each direction is configured by 12 that extends in the Y-axis direction orthogonal to the the motors Mx, My, MZ1, and MZ2 for respectively driving X-axis direction is fixed to the X-axis cart 11. The Y-axis arm the X-axis cart 11, the Y-axis cart 13, the Z-axis cart 15, and 12 is positioned above the loading table 2. AY-axis cart 13 is the primary shaft 18. Supported on the Y-axis arm 12 in a manner that allows move (0099. As described below, the plasma torch 3 and the ment in the Y-axis direction. The X-axis cart 11 and the Y-axis machining head 4 may be moved in the Z-axis direction by cart 13 are respectively driven by an X-axis motor Mx and a means of one motor for driving in the Z-axis direction and one Y-axis motor My which are illustrated in FIG. 3. air cylinder. 0090 The plasma torch 3 is mounted to allow movement 0100. The controller 6 has a hole-cutting functional unit along the Z-axis direction (vertical direction) onto a Z-axis 21, a finishing functional unit 22, an outer periphery-cutting cart 15 supported on the Y-axis cart 13. A distal end part of the functional unit 23, a confirmation functional unit 24, and a plasma torch 3 has a pointed and approximately cylindrical machining line data acquiring unit 25 as illustrated in FIG. 3. shape, and is connected to a plasma power Supply unit 17 (see The hole-cutting functional unit 21, the finishing functional FIG. 3) via a torch cable and the like. A first Z-axis motor MZ1 unit 22, the outer periphery-cutting functional unit 23, and the illustrated in FIG. 3 is provided to allow the plasma torch 3 to confirmation functional unit 24 are configured by a program. be driven in the vertical direction. 0101 The hole-cutting functional unit 21 has the function 0091. The machining head 4 has a second Z-axis motor of forming a hole in the original sheet by means of plasma MZ2 illustrated in FIG. 3 and a primary shaft 18 that is cutting while leaving a machining allowance relative to the movable in the Z-axis direction, and an end mill 19 is finished size. The finishing functional unit 22 has the function mounted on the distal end of the primary shaft 18. of machining the hole to the finished size by inserting the end 0092 A roughing end mill for rough cutting that exerts a mill 19 into the hole formed by the hole-cutting functional Small reaction force when cutting so that the original sheet unit 21 and cutting a thermally-cut end Surface by guiding the US 2015/0027999 A1 Jan. 29, 2015

end mill 19 along the inner peripheral surface of the hole. The machining allowance is minimized. In FIG. 6, the portion cut outer periphery-cutting functional unit 23 has the function of in the cutting machining is depicted by diagonal lines. forming a cutting groove around the outer periphery of a cut 0113. Next in step S2, the height position of the front member by means of plasma cutting and removing the cut surface of the original sheet W0 is measured. Specifically, the member from the original sheet W0. The confirmation func measuring is performed by either of the following two meth tional unit 24 has the function of confirming whether any end ods. material that is plasma-cut by means of the hole-cutting func 0114. In a first measuring method, the distal end of the end tional unit 21 remains inside the hole. mill 19 is allowed to make contact with the front surface of the 0102 The controller 6 is connected to an automatic pro original sheet W0 and the height (distal end position) of the gram device 26. The automatic program device 26 programs end mill 19 in this state is detected (see FIG.5A (b)). The data the data of the machining line in accordance with the shape of obtained from this process and the plate thickness data of the the cut member. The machining data programmed by the original sheet W0 acquired beforehand are used to derive the automatic program device 26 is transmitted to the machining height position of the front surface of the original sheet W0. line data acquiring unit 25 of the controller 6. 0.115. In a second measuring method, the height of the 0103) The height detection sensor 5 and the motors Mx, front surface of the original sheet W0 is measured by the My, MZ1, and MZ2 for respectively driving the movable carts height detection sensor 5 when the protruding length of the 11, 13, and 15 and the primary shaft 18 in the axial directions, end mill 19 from the machining head 4 is known beforehand are connected to the controller 6. The plasma power Supply (see FIG. 5A (c)). Then the height of the front surface of the unit 17 is connected to the controller 6 whereby the genera original sheet W0 is derived from the data obtained by the tion of a plasma arc is controlled. measuring, from the protruding length of the end mill, and from the plate thickness data of the original sheet W0. Machining Method 0116. The position where the end mill 19 or the height 0104. The machining method executed by the above com detection sensor 5 makes contact with the original sheet W0 is bined machining device 1 will be explained with reference to near the hole formed in step S1. FIGS. 4,5A and 5B. Procedures of the machining method are 0117 The first measuring method described above has the illustrated in FIG. 4 and the arrangements of each of the merit that because the end mill 19 makes contact with the components in the steps are illustrated in FIGS.5A and 5B. original sheet W0 and the front surface position of the original 0105 Machining can be performed in the following order sheet W0 is detected by means of a reaction force thereof or when taking out a plurality of cut members from the original electrical conduction, no special sensor is required and the sheet W0. configuration is simple. 0106 Processes of hole cutting X finishing X outer 0118 Conversely, the second measuring method periphery-cutting are implemented in order for each cut described above has the merit that the detection speed is faster member. and the detection accuracy is higher because a sensor used 0107 The processes of hole cutting X finishing are imple especially for height detection is provided. mented altogether on the plurality of cut members, and next 0119. According to the above processing, it is possible to the outer periphery-cutting is implemented altogether on the know whether the distal end of the end mill 19 reaches the plurality of cut members. same height as the rear surface of the original sheet W0 when 0108. After the hole cutting is repeated and the finishing the end mill 19 is lowered by a certain amount. That is, machining is repeated, the outer periphery-cutting is imple because the plate thickness data of the original sheet W0 is mented altogether. acquired by the controller 6 beforehand, the distal end of the 0109 As can be seen from the above methods, the outer end mill 19 and the rear surface position of the original sheet periphery-cutting process is necessarily implemented after W0 are matched by lowering the end mill 19 from the the finishing process. That is, the point in time for implement detected position by the amount of the plate thickness based ing the finishing machining is before the outer periphery on the plate thickness data and the detected distal end position cutting, and the cut members need to be integrated with the of the end mill 19. original sheet. I0120 Accordingly, the lowering amount of the end mill 19 0110. Accordingly, an example of taking out one cut mem is set to the plate thickness of the original sheet W0+C. ber having one hole from the original sheet W0 will be Herein, “C” is set to a value so that dross or a crosspiece of the explained herein. loading table is not cut and so that no incomplete cutting of 0111 First in step S1, the plasma torch 3 is activated and the hole inner peripheral Surface remains. cutting machining of the hole in the original sheet W0 is 0121. In this case, a and a workpiece are loaded and performed (see FIG. 5A (a)). When performing hole cutting machined on a in a machining apparatus having by plasma cutting, the formed hole takes on a reverse trun only the machining head. The height position of the front cated cone shape as illustrated in FIG. 6. That is, a hole surface of the surface plate is acquired beforehand by the diameter d1 on the front surface side of the original sheet in controller. Therefore, measurements of the height position of contact with the plasma arc is larger than a hole diameter d2 the front surface of the original sheet and calculation of the on the rear Surface side. lowering amount as described above are not necessary in a 0112 Accordingly, the hole diameter d1 on the front sur machining apparatus having only the machining head. face side of the original sheet formed by the hole cutting is set 0.122 The thickness of the original sheet W0 and the to be the approximate finished size in the hole cutting in step height positions of the crosspieces 7 on the loading table 2 are S1. That is, in the hole cutting in Subsequent steps, a target acquired as preliminary data by the controller 6 in the com size is set in the hole cutting so that a machining allowance is bined machining apparatus Subject to the present invention. present on the front surface side of the original sheet and the Therefore, cutting machining in Subsequent steps can be per US 2015/0027999 A1 Jan. 29, 2015

formed on the basis of the data without measuring the front I0131 To prevent a reduction in efficiency, the load on the surface of the original sheet W0. motor (using the air motor as described above) for driving the 0123. However, the height of the original sheet W0 loaded end mill 19 is preferably reduced to reduce the cutting speed on the loading table 2 is not uniform due to dross D attached in the finishing machining. Due to the machining allowance, to the crosspieces 7 of the table 2 and due to warping of the the machining is preferably divided into a plurality of steps in original sheet W0 in a device for performing thermal cutting the axial direction as illustrated in FIGS. 9(a) and (b), or the that includes plasma cutting as illustrated in FIG. 7. More machining is divided into a plurality of steps in the radial over, the height of the upper surface of the crosspieces 7 may direction as illustrated in FIGS. 10(a) and (b). In these cases, have a variation of several millimeters because the cross the end mill 19 is guided around a plurality of times. pieces 7 of the table 2 are consumable goods. 0.132. The cutting machining performed with the end mill 0124 Under these conditions, the distalend of the end mill 19 involves up-cutting as illustrated in FIG.11(a) and down 19 may penetrate the original sheet W0 and reach the dross D cutting as illustrated in FIG.11(b). Up-cutting involves caus or the crosspiece 7 as illustrated in FIG. 7(a) when machining ing the edge of the tool to come up against the cut portion and the inner peripheral surface of the hole formed in the original cutting upward. Down-cutting involves causing the edge of sheet W0 on the basis of the previously obtained data as the tool to come up against the uncut portion and cutting mentioned above. In this way, vibration when machining downward. In comparing the two types of , the cutting increases and damage to the end mill 19 may occur when Surface from the down-cutting is rougher but the feed speed is cutting the crosspiece 7 or the dross D. higher. Moreover, at the same feed speed, the reaction force 0.125. Accordingly in step S2, the actual height of the when using the down-cutting is Small and the original sheet original sheet W0, in particular the height of the original sheet W0 does not move very easily. W0 near the formed hole, is measured and the movement of 0.133 Based on the above reason, the machining is per the end mill 19 is controlled in a subsequent process on the formed with down-cutting when finishing machining the hole basis of the measuring result. This process is crucial in the H with the end mill 19 in the present exemplary embodiment. combined machining apparatus Subject to the invention of the 0.134 Here, the height position of the original sheet W0 present application. As illustrated in FIG. 7(b), the finishing may change due to dross Dattached to the crosspieces 7 of the machining can be performed without cutting the dross or the loading table 2. However, due to the previous processing in crosspiece and without incomplete cutting on the inner step S2, the end mill 19 can be lowered precisely to the same peripheral Surface of the hole due to the above processing. position as the rear surface of the original sheet W0. There 0126. Next in step S3, a confirmation is made as to fore, the entire region of the inner periphery end surface of the whether any end material remains inside the hole formed in hole can be cut accurately. Moreover, cutting of the dross D or step S1. That is, normally end material from the inside part of a crosspiece 7 by the end mill 19 can be prevented due to the the hole falls down from a gap between the crosspieces 7 in SaaSOS. the loading table 2 when performing hole cutting in step S1. I0135) In the reverse of the above situation, the height posi However, in Some cases, the end material may becaught on an tion of the original sheet W0 may drop down when wear on end surface of the hole and may remain inside the hole. the crosspieces 7 occurs due to the plasma cutting. In this 0127. Accordingly, in step S3, a confirmation is made as to case, if the height of the front surface of the original sheet W0 whether or not any end material remains inside the hole. cannot be detected, the distal end position of the end mill 19 Specifically, processing to insert the end mill 19 into the hole would not reach the rear surface of the original sheet W0 and is executed. As illustrated in FIG. 5B (a), the distal end of the incomplete cutting may occur. However, this type of defect is end mill 19 hits the end material and cannot be lowered when prevented due to the previous processing in step S2. end material remains inside the hole. By detecting the posi 0.136 Next in step S6, the plasma torch 3 is moved along tion of the end mill 19, the presence of end material inside the the outer periphery of the cut member to cut the outer periph hole can be detected. ery of the cut member. As a result, the cut member having the 0128 If the presence of end material inside the hole is hole formed therein can be taken out from the original sheet confirmed, the routine advances from step S3 to step S4. The machining processing is stopped temporarily in step S4. A WO. warning, such as a flashing light, is issued to an operator. The 0.137 A small machining allowance remains during the operator removes the end material and issues a command to formation of the hole by plasma cutting in the hole-cutting restart the machining processing. process, whereby a load during the cutting machining can be 0129. If no end material is present inside the hole or when reduced in the finishing process. As a result, vibration during the end material is removed, the routine advances to step S5. the cutting machining can be reduced, the stiffness of the In step S5, cutting machining (finishing machining) is per frame can be reduced, and the motor for driving the end mill can be reduced in size. Moreover, the machining reaction formed with the end mill 19. Specifically, the inner periphery force during machining is reduced and a clamping mecha end surface of the hole depicted by the diagonal lines in FIG. nism for holding down the original sheet is made unneces 6 is cut with the end mill 19 (see FIG. 5B (b)). Sary. 0130 FIG. 8 is a plan view of a thermally-cut end surface Hf of the hole H when performing cutting machining with the 0.138 Vibration during machining can be limited and the end mill 19. In the finishing machining, the end mill 19 is first machining reaction force can be reduced since the diameter of inserted into the hole H. The end mill 19 is guided along the the end mill is made to be two times or less the thickness of the thermally-cut end surface Hf which is the inner peripheral original sheet W0. surface of the hole H as indicated by the dashed line arrows (0.139. The height of the original sheet W0 near the hole is and cuts the thermally-cut end surface Hf to machine the hole measured before the finishing machining, and the movement H to the finished size. of the end mill is controlled on the basis of the measurement US 2015/0027999 A1 Jan. 29, 2015

results and the plate thickness data of the original sheet W0. formed especially on large original sheets is enabled by As a result, the inner peripheral surface of the hole can be cut means of a simple and inexpensive combined machining precisely. device. 0140. A confirmation is made as to whether any cut end 1. A combined machining method of forming a hole in an material remains inside the hole from the hole-cutting process original sheet by thermal cutting and machining, and taking and finishing can be performed reliably and accurately since out a cut member including the hole from the original sheet, the finishing machining is performed. Moreover, because the the method including: confirmation is made by means of the end mill, a special a hole-cutting process for forming a hole in the original sensor is unnecessary. sheet by means of thermal cutting while leaving a 0141 Movement of the original sheet W0 can be sup machining allowance relative to a finished size; pressed during the cutting machining since the end mill 19 is a finishing process for inserting a cutting tool into the hole driven by an air motor. Movement of the original sheet W0 formed by the hole-cutting process, cutting a thermally can be Suppressed since a roughing end mill is used as the end cut end Surface by guiding the cutting tool along an inner mill 19 and the machining is performed by down-cutting. peripheral Surface of the hole, and machining the hole to 0142. The present invention is not limited to the above the finished size; exemplary embodiments and various changes and modifica an outer periphery-cutting process for cutting an outer tions may be made without departing from the spirit of the periphery of the cut member by means of thermal cutting invention. and taking out the cut member from the original sheet; 0143. While machining is temporarily interrupted and and then is started after waiting for the removal of end material by a confirmation process for confirming whether or not ther the operator when end material is present inside the hole in the mally-cut end material remains inside the hole in the present exemplary embodiment, the end material may also be hole-cutting process between the hole-cutting process removed automatically. and the finishing process. 0144. The tool to be used for finishing machining is not 2. The combined machining method according to claim 1, limited to an end mill. Another cutting tool such as a grinder wherein may be used. the thermal cutting during the hole-cutting process and the 0145 The shape of the hole to be machined in not limited outer periphery-cutting process is plasma cutting by to a circular shape. For example, the present invention is generating a plasma arc on the front Surface side of the applicable in the same way when the shape of the hole is a slot original sheet; and or a rectangle. the thermal cutting is performed by leaving a machining 0146 While the first Z-axis motor MZ1 for driving the allowance on an original sheet front Surface side end plasma torch 3 and the second Z-axis motor MZ2 for driving section of the hole in the hole-cutting process. the machining head 4 are provided in the present exemplary 3. The combined machining method according to claim 1, embodiment, the mechanism for moving the motors in the wherein Z-axis direction is not limited to the present exemplary the thermal cutting during the hole-cutting process and the embodiment. outer periphery-cutting process is laser cutting that irra 0147 For example, the plasma torch 3 and the machining diates a laser orgas cutting that emits a gas from the front head 4 may be supported on a cart that is capable of moving Surface of the original sheet; and in the Z-axis direction, and the cart may be driven in the the thermal cutting is performed by leaving a machining Z-axis direction by one motor, and either the plasma torch 3 or allowance on an original sheet rear Surface side end the machining head 4 may be driven in the Z-axis direction section of the hole in the hole-cutting process. with an air cylinder. 4. The combined machining method according to claim 1, 0148. In this case, the plasma torch 3 is preferably driven wherein with the air cylinder because the plasma torch 3 is less sus machining is performed without clamping the original ceptible to bearing a reaction force during machining than the sheet from the hole-cutting process to the outer periph machining head 4. ery-cutting process. 0149 While plasma cutting is used as the thermal cutting, the present invention can be applied in the same way for 5. The combined machining method according to claim 1, combined machining of the machining and thermal cutting wherein that makes use of another cutting such as laser orgas cutting. a rotating cutting tool is used for cutting the thermally-cut 0150. When forming a hole by means of a laser orgas, the end Surface of the hole in the finishing process; and diameter on the original sheet front surface side of the hole a cutting tool diameter is two times or less than the thick which is the laser irradiation side or the gas emission side ness of the original sheet. tends to be smaller than the diameter of the rear surface side, 6. The combined machining method according to claim 1, which is the reverse of the tendency in plasma cutting. further including 0151. Accordingly, when cutting the hole with a laser or a measuring process for measuring a height position of the with gas, the thermal cutting must be performed so that the hole as a previous process of the finishing process; and machining allowance remains on the end part of the original a height position of the cutting tool is controlled in the sheet rear Surface side of the hole. In this case, by making a finishing process on the basis of measurement results target size on the rear Surface side the approximate finishing from the measuring process and plate thickness data of size in the hole-cutting process, the cutting amount in the the original sheet. finishing machining can be greatly reduced. 7. (canceled) 0152. According to the exemplary embodiment of the 8. The combined machining method according to claim 1, present invention, thermal cutting and machining to be per wherein US 2015/0027999 A1 Jan. 29, 2015

the confirmation process is performed by inserting the wherein, the control unit has cutting tool used in the finishing process into the hole. a hole-cutting functional unit for forming a hole in the original sheet by means of thermal cutting while leaving 9. The combined machining method according to claim 1, a machining allowance relative to the finished size of the wherein hole; the thermally-cut end surface of the hole formed in the a finishing functional unit for inserting a cutting tool into hole-cutting process is cut by an end mill in the finishing the hole formed in the hole-cutting process, cutting a process. thermally-cut end Surface by guiding the cutting tool 10. The combined machining method according to claim 1, along an inner peripheral Surface of the hole, and machining the hole to the finished size; wherein an outer periphery-cutting functional unit for cutting an the rotating cutting tool is driven with an air motor in the outer periphery of the cut member by thermal cutting finishing process. and taking out the cut member from the original sheet; 11. A combined machining device for forming a hole in an and original sheet by thermal cutting and machining, and taking a confirmation functional unit for confirming whether or not thermally-cut end material is remaining inside the out a cut member including the hole from the original sheet, hole. the device comprising: 12. The combined machining device according to claim 11, a loading table on which an original sheet is loaded; wherein a first head for performing thermal cutting on the original a second head has a cutting tool having a diameter that is sheet loaded on the loading table; two times or less than the thickness of the original sheet. 13. (canceled) a second head for performing machining on the original 14. The combined machining device according to claim 11, sheet loaded on the loading table; wherein a movement mechanism for moving the first and second the control unit confirms the presence of the end material heads in the horizontal direction and in the vertical direc by inserting a cutting tool attached to the second head tion relative to the loading table; into the hole. 15. The combined machining device according to claim 11, a height position detection sensor for detecting a position wherein in the vertical direction of the original sheet loaded on an end mill is attached to the second head. the loading table; and 16. The combined machining device according to claim 11, a control unit for controlling relative movement of the first wherein and second heads relative to the loading table, and for the second head has an air motor for driving the cutting controlling thermal cutting and machining performed by tool. the first and second heads;